Process for the vapor phase aluminization of a turbomachine metal part and donor liner and turbomachine vane comprising such a liner

ABSTRACT

An aluminization process by vapor phase deposition for high-temperature oxidation protection of a metal turbomachine part. The part including a cavity into which a metal component is introduced and assembled from an opening in the part. A halide is formed by reaction between a halogen and a metal donor containing aluminum, then the halide is transported by a carrier gas in order to come into contact with the metal part, wherein the metal component has first, before the implementation of the process, been surface-enriched with aluminum in order to serve as an aluminum donor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 12/245,052now U.S. Pat. No. 8,202,574 filed Oct. 3, 2008, the entire contents ofwhich is incorporated herein by reference. U.S. application Ser. No.12/245,052 is based upon and claims the benefit of priority from priorFrench Patent Application Nos. 08-52921 and 07-06932 filed Apr. 30, 2008and Oct. 3, 2007, respectively.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the deposition of an aluminum coatingon a metal part, especially on a hollow metal part comprising aninternal liner. It more particularly targets the application of such acoating to hollow turbomachine vanes incorporating a liner fordistributing coolant.

2. Discussion of the Background

A gas turbine engine, such as is used for propulsion in the aeronauticalfield, comprises an atmospheric air inlet which communicates with one ormore compressors, generally including one fan, that are rotated aboutone and the same axis. The primary stream of this air, after having beencompressed, supplies a combustion chamber arranged annularly around thisaxis and is mixed with a fuel to provide hot gases downstream to one ormore turbines through which these gases are expanded, the turbine rotorsdriving the compression rotors. The engines operate at a temperature ofthe engine gases at the turbine inlet that is sought to be as high aspossible because the performances are linked to it. For this purpose,the materials are chosen to withstand these operating conditions and thewalls of parts swept past by the hot gases, such as the nozzles or therotating turbine blades, are provided with cooling means. Furthermore,due to their metallic composition as superalloy based on nickel orcobalt, it is also necessary to protect them from erosion and corrosioncaused by the constituents of the engine gases at these temperatures.

One known means for providing the protection of these parts is todeposit an aluminum-based coating on the surfaces susceptible to attackby the gases. The aluminum is attached to the substrate by metalinterdiffusion and forms a protective oxide layer at the surface. Thethickness of the coating is of the order of a few tens of microns.

The present invention relates to the technique, known per se, ofdepositing aluminum in the vapor phase, otherwise known as vapor phasealuminization. According to the process, the parts to be treated areplaced in a chamber in which the atmosphere is composed of a mixture ofan inert or reducing gas, for example argon or hydrogen, and an activegas comprising an aluminum halide. At the reaction temperature, between900° C. and 1150° C., the halide decomposes at the surface of the partto gaseous halogen and aluminum which diffuses into the metal.

The halide is produced by placing, in the chamber with the parts to betreated, blocks of aluminum metal or of an aluminum alloy that form thedonor, in the presence of granules of a halogen compound, a chlorine orfluorine compound, that form the activator. The inert gas is circulatedover the activator at a temperature that allows the sublimation of thehalogen which is entrained over the donor and with which it reacts toproduce the metal hydride which, at this temperature, is in the vaporform. The halide then decomposes in contact with the metal substrate tobe coated, allowing the deposition of aluminum; the gaseous halogen isreformed.

When the stator parts and also the rotor parts are provided withinternal cavities through which a coolant and air withdrawn from thecompressor travel, it was observed that the walls of these cavities werealso subject to corrosion. Returns of parts used in engines operating incertain environments have shown an attack of these surfaces. Thefollowing have been found, for example, internal corrosion of thenozzles, releases of flakes of corrosion into the cavity of the nozzles,blocking of the trailing edge vent holes, etc. Protection for thesetypes of parts is therefore also necessary.

The vapor phase aluminization method is particularly suitable a priorifor applying a protective coating since the carrier gas and the activecomponents are capable of penetrating into the narrow passages forcirculation of the coolant insofar as these passages are open. Realityshows that this is not the case. The thickness of the protective layeris not uniform; it greatly decreases starting from the access orificesof the cavities. Furthermore, accumulations are formed at the vent holesof the cavities, reducing the flow area and the cooling properties ofthe part.

In Patent Application FR 2830874 in the name of the Applicant, a processis described for the vapor phase aluminization of metal turbomachineparts provided with holes and cavities that communicate with theoutside, according to which a gaseous precursor of the deposit to bemade comprising an aluminum compound is brought, by means of a carriergas, into contact with the surfaces of the part placed in a chamber, thecarrier gas is either helium or argon and the pressure in the chamber ischosen so that the mean free path of the carrier gas molecules is twotimes greater than that of the argon molecules under atmosphericpressure. The mean free path of the molecules is usually defined as theratio 1/P×D² where P is the pressure in the chamber and D is themolecular diameter.

By lengthening the mean free path of the carrier gas molecules, thediffusion of the halide in the internal channels is increased and thethickness of the deposit in the zones that are less accessible via theconventional method is increased; the overall protection thereof isimproved. The increase in the free path results either from the choiceof the carrier gas, here helium, or from a reduction in the pressure ascan be deduced from the above formula.

SUMMARY OF THE INVENTION

The subject of the invention is a variant of the process that makes itpossible to obtain a coating of the walls of the internal cavities overthe entire surface with a sufficient thickness.

The invention relates to hollow parts with one cavity and one opening atleast through which the cavity communicates with the outside. It relatesto such parts, provided with a component such as an internal liner,inside the cavity, introduced through the opening and assembled with thepart. Such a part is represented in FIG. 1. This is the cross section ofa nozzle of a low-pressure stage in a two-shaft gas turbine engine. Thenozzle guide vane 1 comprises a part manufactured by casting metal in ashell mold. This part, hatched in the figure, is formed from a hollowblade 2 between two platforms 3 and 4. The cavity of the blade 2communicates via its two ends, respectively, on one side with an opening5 for supplying coolant and, on the other side with a fluid outlet 6.Inside the cavity of the blade 2 a liner 9 of substantially cylindricalshape is positioned. The liner is welded or brazed to the side of theopening 5 for supplying cooling air via a peripheral brazing/weldingalong the edge of the opening of the cavity. The other end of the lineris introduced into a cylindrical housing that communicates with theoutlet 6, without being welded thereto in order to allow the relativeexpansion of the liner relative to the blade during transient operatingsteps. The liner is perforated over its length and makes a space withthe inner wall of the blade so that cooling air coming from the opening5 for supplying air passes partly through the perforations of the linerand forms a plurality of air jets that cool the wall of the blade byimpact and convection. This air is then discharged via vents arranged inthe vicinity of the trailing edge of the blade. The air that has notpassed through the wall of the liner is guided toward the opening 6 inorder to be conveyed to other parts of the machine.

During manufacture, the liner 9, produced separately from the blade, isintroduced into the blade by being slid through the orifice 5 thenbrazed in the vicinity of the mouth as mentioned above. The lower part,in the figure, remains free to expand and slide in the housing formed bythe opening 6.

Conventionally, the aluminization treatment of a part such as the latteris carried out after it has been assembled.

In accordance with the invention, the aluminizing deposition inside thecavity is substantially improved with the following process, that can beapplied to any part comprising a component that may be slid through anopening and assembled inside the part.

The aluminization process by vapor phase deposition for high-temperatureoxidation protection of a hollow metal turbomachine part,

-   -   said part comprising a cavity into which a metal component is        introduced and assembled from an opening in said part,    -   according to which process a halide is formed by reaction        between a halogen and a metal donor containing aluminum, then        the halide is transported by a carrier gas in order to come into        contact with said metal part,    -   wherein the metal component has first, before the implementation        of the process, been surface-enriched with aluminum in order to        serve as an aluminum donor.

Providing a donor inside the cavity that is composed of thesurface-enriched component allows an effective deposition. In particularthe problem of accessibility from the outside of the part is solvedwhile controlling the amount of internal donor.

Specifically, the component is preferably coated with a layer formed bymetal deposition. This deposition may have been carried out by anymethod available to a person skilled in the art: aluminization by vaporphase deposition (SVPA or CVD, aluminization by pack cementation),vacuum deposition (PVD), thermal spraying, electrodeposition orimmersion in a bath (dip coating), etc.

In particular the amount of donor is controlled by the thickness of thelayer; it is, for example, between 10 μm and 150 μm, preferably between20 and 90 μm.

The layer contains at least 15 wt % of aluminum but may also comprise atleast one element known for its properties of improving the oxidationresistance and that is included in the set (Cr, Hf, Y, Zr, Si, Ti, Ta,Pt, Pd, Ir), in particular the element Cr.

As has been explained above, the process is advantageously suitable forthe aluminization treatment of a hollow turbomachine vane. Saidcomponent is then composed of the perforated liner for distributingcoolant inside the cavity.

The vane is a nozzle guide vane with a blade provided with a cavity anda liner in the cavity. The liner is introduced, after having beenenriched with donor metal, via an opening made in one end of the blade.Next, the liner is welded via one end to the wall of the blade on theside of the opening for introducing the liner into the cavity. The lineris, for example, made of a cobalt-based alloy for the mechanicalproperties of the latter of resistance to vibrations and to friction.

The use of an aluminum-donor liner is particularly advantageous insofaras the quality of the internal coating of the cavities of the vanes issubstantially improved without having to modify the conventionalgas-phase aluminization process. The vane and the donor liner areassembled in almost the same way as a vane with a non-aluminized liner,the only modification relating to the brazed zone which preferably mustremain uncoated, then it is aluminized in the conventional manner.

The vanes comprising a donor liner may be nozzle guide vanes for thehigh-pressure stages of the turbine of a gas turbine engine or else forthe low-pressure stages of the turbine of such an engine.

BRIEF DESCRIPTION OF THE DRAWINGS

A nonlimiting embodiment of the invention will now be described withreference to the drawings, in which:

FIG. 1 represents a nozzle guide vane with an internal cavity and aliner for distributing cooling air introduced into this cavity;

FIG. 2 shows an aluminization installation that is suitable forimplementing the process of the invention; and

FIG. 3 shows the coating thickness obtained internally both by the priorart technique and the technique according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 2 shows very schematically a conventional vapor phase aluminizationinstallation in which the process of the invention is carried out.

A chamber 12 is mounted inside a furnace 4 capable of heating the partsto a temperature of 1200° C. Placed in this chamber are boxes 16, herethree superposed boxes, with a cover 16′. These boxes contain the partsto be treated P, for example turbine nozzles, with the metal donor D inpowder form or in the form of blocks and the activator A. The chamber 12comprises a purging carrier gas supply 18, a flushing carrier gas supply19 and an outlet 20 controlled by a valve 21.

After having positioned the parts, the donor and the activator in theboxes 16, the chamber 12 is first purged by introducing the carrier gas,for example argon, through the conduit 18. The supply is interruptedwhen the air in the chamber has been replaced by argon. Next, thefurnace is heated while supplying the chamber with argon via the conduit19. The excess gas is discharged via the conduit 20. At the activationtemperature of the activator A, the halogen, chlorine or fluorine, isreleased. By coming into contact with the donor, the halogen reacts withthe metal and forms a halide. The halide vapor thus formed circulatesinside the boxes 16 and comes into contact with the metal parts P. Atthis moment, the halide decomposes and releases the metal which isdeposited on the part.

The argon is continuously introduced, as a gentle flushing, via theconduit 19 into the chamber 12 and is discharged via the conduit 20. Thetreatment time is between 2 and 6 hours.

In accordance with the invention, the donor is brought together with thecavity by using the liner as a donor.

Prior to the aluminization treatment, the part is prepared by assemblingan aluminum-enriched liner and the part that has just been cast. Theliner is introduced through the passage 5 for supplying cooling air inthe blade. Next, the upper edge 9′ of the liner 9 is brazed to the wallof the opening in the blade.

The liner has been enriched with aluminum by any means available to aperson skilled in the art. The mode of applying the coating to thisliner may be that described by the patent itself (vapor phasealuminization), the liners replacing the parts to be treated P in thechamber 12 of the SVPA furnace 4.

The liner may thus have itself been treated beforehand by vapor phasealuminization for the purpose of producing a layer over the entiresurface. The thickness of the layer is determined so as to have asufficient amount of aluminum to react with the halogen and form avapor-phase halide during the aluminization operation of the part. Asthe donor is close to the surfaces to be treated, the depositionobtained is greater than that which could be obtained by theconventional method.

The advantage of this solution relative to another solution, which mightconsist in placing a donor basket inside the cavity, is in enabling thepart that has already been assembled to be treated. The use of a basketin an intermediate step would make it necessary to treat the partwithout the liner then to mount the liner on the part, the walls ofwhich are coated with a layer of aluminum, which requires a particularadaptation of the brazing means.

Furthermore, it is not necessary to develop a specific technique forcleaning the inside of the cavity of donor residues.

In FIG. 3 the distribution, on the y-axis, of the thickness of thecoating obtained on the walls of the cavity is represented. The curve Acorresponding to the prior art shows that the coating is very poorlydistributed between the leading edge and the trailing edge both alongthe lower surface and the upper surface. The curve B represents thethickness of the coating obtained with the donor liner. It is morehomogeneous and non-zero. The zone C shows the external thickness.

The invention claimed is:
 1. A hollow turbomachine vane including aliner for distributing cooling air, the liner being cylindrical, theliner including a first end which is welded or brazed to a coolantsupplying opening of the vane and a second end which is introduced intoand not welded to a housing which communicates with an outlet of thevane, and a surface of the liner being coated, at least partially, witha layer of at least 15 weight percent of aluminum, wherein a thicknessof the layer of aluminum is determined so as to have a sufficient amountof aluminum to react with a halogen to form a vapor-phase halide duringan aluminization operation of an internal surface of the vane, andwherein the internal surface of the vane is free of a coating comprisingaluminum.
 2. The vane as claimed in claim 1, wherein the aluminum layeris between 10 and 150 μm.
 3. The vane as claimed in claim 2, wherein thealuminum layer is between 20 and 90 μm.
 4. A turbomachine nozzlecomprising the hollow vane of claim
 1. 5. The vane as claimed in claim1, wherein the liner is perforated with at least one perforation.
 6. Thevane as claimed in claim 5, wherein a space is provided between theliner and an inner wall of the vane such that cooling air coming fromthe coolant supplying opening passes through at least one perforation ofthe liner to form air jets.
 7. The vane as claimed in claim 1, whereinthe liner comprises a cobalt-based alloy.
 8. The vane as claimed inclaim 1, wherein the layer which coats the liner further comprises atleast one of Cr, Hf, Y, Zr, Si, Ti, Ta, Pt, Pd, and Ir.
 9. The vane asclaimed in claim 1, wherein a zone of the surface of the liner that isbrazed is uncoated.